Liebherr-Components Deggendorf – digital shop floor with 4APS, 4BDE, 4MDE and 4PRO

Location: 94469 Deggendorf, Germany · Industry: Automotive, precision parts, injection systems, component manufacturing, metalworking · Products: Diesel and gas injectors, injection systems, micro-precision parts, automotive components · ERP: Infor:LN · Website: https://www.liebherr.com/de-de/firmengruppe/standort/deggendorf-profil-3705450 · S4P modules: 4APS, 4BDE, 4MDE, 4PRO

Initial situation

The climate-controlled production at Liebherr-Components Deggendorf is characterised by highest precision, cleanroom assembly, complex processes and demanding manufacturing conditions. In this environment, the need for continuous real-time information from production grows in order to assess statuses, progress and deviations quickly and reliably.

Challenge

After the company was founded in 2015, growth in 2018 led to the following situation: despite the ERP system Infor:LN and a Forcam MES, the lack of transparency in production and machine data made it increasingly difficult to monitor manufacturing processes reliably, detect faults early and take well-founded decisions on the shop floor and in production control. In this complex production environment with high quality requirements a digital link between planning, production and data acquisition was needed. In a lengthy and intensive system selection process with competitor benchmarks, reference visits and a proof of concept, the final decision was taken in 2019 to introduce the MES/APS solutions from S4P and Inform from Aachen, who have been an OEM partner of S4P since 2012 and market the complete S4P portfolio under the name FELIOS|MES.

Solution

Together with Inform, S4P introduced the following solutions in dedicated sub-projects: bidirectional interfaces to the Infor:LN ERP, FELIOS|APS for day-accurate multi-resource planning, FELIOS|SPE for shift planning, FELIOS|FLS for real-time multi-resource planning, FELIOS|BDE for shop-floor data collection, FELIOS|SPC for statistical process control and claim tables, FELIOS|MDE for manual machine data acquisition, FELIOS|PRO for warehouse management (WMS) and logistics control, plus the integration of e-labels, handhelds, RTLS object tracking and Liebherr applications. Together these modules provide production feedback, machine states and relevant manufacturing information within a fully integrated digital environment.

Results and benefits

Better availability and usability of production data enable processes to be steered and evaluated with greater transparency. This supports faster reactions to deviations, improves the information basis for shop-floor management and creates an important foundation for more efficient workflows, higher process reliability and data-driven production improvement.